Realisation of responsive and sustainable reconfigurable manufacturing systems

Figures & data

Table 1. Resent publications on sustainable reconfigurable manufacturing.

Author	Year	Methodology	Sustainability indicator
Choi et al.	2015	Muti-objective optimisation	Energy consumption
Zhang et al.	2015	Reconfigurable timed net condition/event systems	Energy efficiency
Huang et al.	2018	Mathematical	Energy consumption, Water consumption
Liu et al.	2018	ε-Constraint method, NSGA-II & MOSA	Energy cost
Khezri et al	2019	Augmented ε-constraint	Energy consumption, Waste
Cerqueus et al.	2020	GA	Energy cost
Khezri et al	2021	AUGECON, NSGA-II, SPEA-II	Energy consumption, Waste
Massimi et al.	2020	Mathematical	Energy consumption
Khettabi et al.	2021	GA& TOPSIS	Carbon emission
Khettabi et al.	2022	NSGA-II, New NSGA-III	Hazardous liquid waste, Carbon emission

Figure 1. Design for responsive and sustainable reconfigurable RMS.

In the design of robustly validated pre-emptive DEF adaptable and sustainable to dynamic and ambitious market demands, foundational requirements are identified into four groups, adaptability, operability, reconfigurability and sustainability.

Figure 2. Problem description – Design and analyse of responsive and sustainable RMS.

We design an n-stage engineering system with different stages and different operations through the process.

Figure 3. Proposed method – Implication for DEF development.

This method has the capacity to generate a decision space for RMS reconfiguration strategy by applying robust design analysis.

Figure 4. The proposed specific process to explore the decision network for sustainable RMS reconfiguration strategy.

This method includes four steps which are: Scenarios Discovery, Decision Model, Decision Interaction and Decision Network.

Figure 5. The six axes of degree of freedom.

In equation o lr = t lr + h 1 r, olr represents the motion requirement for the rth direction of the lth operation and olr is defined as the degrees of freedom of motion on the X-, Y-, Z-, A-, B-, and C-axes.

Figure 6. Solution space exploration in weak-weak interaction (a), strong-strong interaction (b), and strong-weak interaction (c).

According to the information exchange between RMT configuration design and RMT configuration design process, the exploration process is divided into the following three situations: weak-weak interaction, strong-strong interaction and strong-weak interaction.

Figure 7. Decision network for exploring the sustainable RMS reconfiguration strategy.

Long Description: First (Step A), the input information is preprocessed. which divides the design information into design variables, parameters and gales. Second (Step B and F), The relationship between design parameters and variables is defined based on the key features of different RMS granularity configuration and the corresponding performance indicators. At the same time, a single-grain configuration design scheme is explored. Third (Step C and F), the interactions between different granularity configuration designs and established exploration of the RMS reconfiguration method are considered. Finally, weights from system simulation are derived in the Fourth Step (Step D) or to analyse the application scenario (Step E).

Table 2. RMT basic modules and the corresponding energy consumption (Sullivan, Burnham, and Wang 2010).

Num	Module name	Simplified module	Node domain	Node function	Energy consumption (MJ/KG)
1	Spindle head			Modules with a variety of tools	0.25
2	Fixture			Modules for positioning the workpiece	0.2
3	Slider			Modules for moving tool and work-piece left and right	3.5
4	Cross-slider			Modules for moving tool and work-piece forward and backward	3.5
5	Column			Modules for moving tool and work-piece up and down	4
6	Rotary table			Modules for allowing tool and work-piece rotary motion	4.5
7	Base			Modules for support and connection of the modules	0.17

Figure 8. The example of the L4 (right) and V8 (left) engine block (a) and three types of the cylinder block (b) (Abbas and ElMaraghy 2016).

There are two different cylinder block of the L4 and V8 engines, which contain exact complex rigid box part of each engines. After that, the processing routes of three engine blocks are shown, which contain key operating information of each engines.

Table 3. Key operation for L4, V6 and V8 engine cylinder production (Milisavljevic-Syed et al. 2020a).

Type	Num	Manufacturing operations	Manufacturing Features	Reference Surface
L4	1	Op11	XYZ	Undersurface and two locating pin holes
	2	Op12	XYZ	Side datum, position shoulder and two pin holes
	3	Op13	XYZ	Side datum, position shoulder and two pin holes
	4	Op14	XYZ	Side datum, position shoulder and two pin holes
	5	Op15	YZB	Side datum, position shoulder and two pin holes
	6	Op16	YZC	Side datum, position shoulder and two pin holes
V6 and V8	1	Op21	XYZ	Undersurface and two locating pin holes
	2	Op22	XYZ	Side datum, position shoulder and two pin holes
	3	Op23	XYZ	Side datum, position shoulder and two pin holes
	4	Op24	XYZ	Side datum, position shoulder and two pin holes
	5	Op25	XYZ	Side datum, position shoulder and two pin holes
	6	Op26	XYZB	Side datum, position shoulder and two pin holes
	7	Op27	YZB	Side datum, position shoulder and two pin holes
	8	Op28	XYZBC	Side datum, position shoulder and two pin holes

Figure 9. The RMS initial configuration in text example.

A block diagram has a total of 9 work stations, of which six are RMTs and three are RIMs. The specific configuration of each RMT is shown in the corresponding configuration tree.

Figure 10. The solution of Phase A with (a) and without (b) considering energy consumption.

Two block diagrams show the conversion between different part families led to the reconfiguration of the system. When considering energy consumption, part of RMT corresponding configuration tree changes.

Figure 11. The solution of Phase B with (a) without (b) considering energy consumption.

Two block diagrams show the conversion of different parts between the same part family. When considering energy consumption, part of RMT corresponding configuration tree changes.

Figure 12. Results of sustainability for each phase with and without considering energy consumption.

From left to right, the bar graphs show the total energy consumption and the sustainability of the RMS configuration design for each phase.

Liu, Ming, Rongfan Liu, Zhanguo Zhu, Chengbin Chu, and Xiaoyi Man. 2018. “A bi-Objective Green Closed Loop Supply Chain Design Problem with Uncertain Demand.” Sustainability 10 (4): 967. https://doi.org/10.3390/su10040967.

 Web of Science ®Google Scholar

Cerqueus, Audrey, Paolo Gianessi, Damien Lamy, and Xavier Delorme. 2020. “Balancing and Configuration Planning of RMS to Minimize Energy Cost.” Paper Presented at the Advances in Production Management Systems. Towards Smart and Digital Manufacturing: IFIP WG 5.7 International Conference, APMS 2020, Novi Sad, Serbia, August 30–September 3, 2020, Proceedings, Part II.

 Google Scholar

Massimi, Elisa, Amirhossein Khezri, Hichem Haddou Benderbal, and Lyes Benyoucef. 2020. “A Heuristic-Based non-Linear Mixed Integer Approach for Optimizing Modularity and Integrability in a Sustainable Reconfigurable Manufacturing Environment.” The International Journal of Advanced Manufacturing Technology 108: 1997–2020. https://doi.org/10.1007/s00170-020-05366-y.

 Web of Science ®Google Scholar

Khettabi, Imen, Lyes Benyoucef, and Mohamed Amine Boutiche. 2021. “Sustainable Reconfigurable Manufacturing System Design Using Adapted Multi-Objective Evolutionary-Based Approaches.” The International Journal of Advanced Manufacturing Technology 115 (11-12): 3741–3759. https://doi.org/10.1007/s00170-021-07337-3.

 Web of Science ®Google Scholar

Sullivan, John Lorenzo, Andrew Burnham, and Michael Wang. 2010. Energy-consumption and Carbon-Emission Analysis of Vehicle and Component Manufacturing. Argonne, IL, USA: Argonne National Lab.(ANL).

 Google Scholar

Abbas, Mohamed, and Hoda ElMaraghy. 2016. “Design Synthesis of Machining Systems Using co-Platforming.” Journal of Manufacturing Systems 41: 299–313. https://doi.org/10.1016/j.jmsy.2016.10.001.

 Web of Science ®Google Scholar

Milisavljevic-Syed, Jelena, Janet K Allen, Sesh Commuri, and Farrokh Mistree. 2020a. Architecting Networked Engineered Systems. Springer.

 Google Scholar

Data availability statement

The data that support the findings of this study are available from the corresponding author, Milisavljevic-Syed, J., upon reasonable request.